Multi-conductor electrical socket and method of making the same

ABSTRACT

A multi-conductor electrical socket comprising a substantially rectangular and partially hollow insulating housing with a plurality of external insulated electrical lead wires extending into one end of the housing and terminating therein. Each lead wire is connected or crimped at its housed end to one end of a terminal for electrical connection therewith, the other end of each terminal being exposed for engagement with an external plug. Prior to the crimping operation, the terminals and lead wires are placed on a platform or base of the housing where they are thereafter simultaneously connected or crimped together, utilizing the platform or base as an effective anvil.

United States Patent Bury [s 1 MULTI-CONDUCTOR ELECTRICAL SOCKET AND METHOD OF MAKING THE SAME [72] lnventor:

[73] Assignee: Molex Incorporated, Downers Grove, Ill. [22] Filed: May 19, 1970 [21] Appl. No.: 38,786

Allen J. Bury, Prospect Heights, 111.

- Martines ..29/630 A [151 3,668,615 1 June 6,1972

3,259,873 7/1966 Parkinson et al. ..29/630A FOREIGN PATENTS OR APPLICATIONS 233,059 11/1959 Australia ..339/196 R 1,033,433 7/1953 France "339/276 T Primary Examiner-Joseph H. McGlynn AttomeyOlson, Trexler, Wolters & Bushnell [57] ABSTRACT A multi-conductor electrical socket comprising a substantially rectangular and partially hollow insulating housing with a plurality of external insulated electrical lead wires extending into one end of the housing and terminating therein. Each lead wire is connected or crimped at its housed end to one end of a terminal for electrical connection therewith, the other end of each tenninal being exposed for engagement with an external plug. Prior to the crimping operation, the terminals and lead wires are placed on a platform or base of the housing where they are thereafter simultaneously connected or crimped together, utilizing the platform or base as an effective anvil.

8 Claims, 12 Drawing figures PATENTEDJUH 61972 SHEET 10F 2 PATENTEnJun 6 m2 SHEET 2 0F 2 mfjarly MULTI-CONDUCTOR ELECTRICAL SOCKET AND METHOD OF MAKING THE SAME DISTINCTIONS OVER THE PRIOR ART AND OBJECTS This invention relates generally to electrical connecting devices and more particularly to multi-conductor electrical sockets and a method of assembling the same.

Electrical connectors, i.e., plugs or sockets, are well known in the art. These plugs or sockets conventionally comprise one or more electrical terminals which are crimped or otherwise connected at one end to insulated conductors. In accordance with one preferred construction, terminals are crimped onto terminals and the terminals and associated conductors are then inserted into an insulated housing with the front ends of the terminals being exposed for engagement with another electrical connecting device. The prior art terminal may generally be described as an elongated irregularly shaped cylinder having at its crimping end a pair of ferrules which are arranged to engage both the wire and the insulation of the conductors by a crimping operation.

The crimping operation is generally performed by supporting the terminal on an anvil so that the ferrules extend upward. A lead wire is then positioned between the ferrules and a die is pressed thereagainst for forging the ferrules and lead wire into a substantially integral unit.

The major drawback with the prior art connecting device of the above-described type is in the manner of assembling it. Specifically, each lead wire and associated terminal are individually crimped or connected together and thereafter inserted into theinsulated housing. This is time-consuming and uneconomical.

Accordingly, a general object of the present invention is to provide a novel and improved electrical connecting device which is assembled together in one rapid operational step.

Another object of the present invention is to provide a novel and improved electrical connecting device which is rapidly and economically assembled together so as to form a releasable electrical connection.

A more specific object of the present invention is to provide a novel and improved multi-conductor electrical socket which includes a plurality of electrical terminals which are simultaneously crimped to associated conductors while the terminals rest within and on a housing, the housing providing an effective anvil for the crimping operation.

These and otherobjects and features of the invention will become more apparent from a reading of the following descriptions.

SUMMARY OF THE INVENTION The foregoing problems are overcome and the foregoing objectives are attained by providing a multi-conductor electrical socket which may be substantially assembled in one rapid I operational step. The socket comprises an insulating housing with a plurality of insulated electrical lead wires or conductors extending into one end of the housing and tenninating therein. Each lead wire is crimped at its housed end to one end of a terminal, also located within the housing, for electrical connection therewith, the other end of each terminal being appropriately exposed for engagement with an external electrical connector such as a cooperating plug. The housing includes a base or platform for supporting the crimping ends of the terminals and a movably connected cover for exposing the terminals prior to the crimping operation thereof. The socket is assembled by first inserting the terminals into the housing and onto the base or platform with a conductor positioned in engaging relationship with each terminal. The terminals and corresponding conductors are thereafter simultaneously forged together by the pressure of a cooperating die, the base or platform acting as a counter-die or anvil.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings:

FIG. 1 is a perspective view of the back end of the multiconductor electrical socket according to the invention, the socket being shown in its assembled condition;

FIG. 2 is a perspective view of the front end of the multiconductor electrical socket shown in its assembled condition;

FIG. 3 is a perspective view of the multi-conductor electrical socket in combination with a crimping die, the socket being shown prior to the crimping operation;

FIG. 4 is a perspective view of the multi-conductor electrical socket in combination with a crimping die, the socket being shown during crimping operation;

FIG. 5 is a side sectional view taken along line 5-5 of FIG.

FIG. 6 is a side sectional view taken along line 6-6 of FIG. 4;

FIG. 7 is a plan sectional view taken along line 7-7 of FIG.

FIG. Sis a back sectional view taken along line 8-8 of FIG.

FIG. 9 is a cross-sectional view taken along line 9-9 of FIG. 7;

FIG. 10 is a cross-sectional view taken along line 10-10 of FIG. 7;

FIG. 1 l is an elevational view ofa portion of the back end of a modified socket according to the invention; and

FIG. 12 is a perspective view of a portion of the socket of FIG. 1 1.

DETAILED DESCRIPTION Referring now in detail to the drawings, wherein like numerals indicate like components, a multi-conductor electrical socket constructed in accordance with the present invention is indicated generally by the reference numeral 10. As seen in its assembled condition in FIGS. 1 and 2, the socket com rises a substantially rectangular and partially hollow insulating housing 12 with a plurality of external insulated electrical lead wires or conductors l4 entering into one end of the housing and terminating therein. Each lead wire is connected or crimped at its housed end to one end of a terminal 16, as can best be seen in FIG. 7, for electrical connection therewith, the other end of each terminal being exposed for connection with an external electrical connector such as a plug. While the socket conventionally functions to join one electrical component to another, it will be seen hereinafter that its unique structure enables it to be rapidly and economically assembled in a rather novel manner.

The housing 12, which is preferably made of hard plastic such as nylon and molded into a unitary structure, includes a rectangular plug connecting forward portion 18 which includes in its front end a rectangular opening or cavity 20 for receiving therein a cooperating external plug which is not shown. As seen best in FIG. 7, the depth of opening 20 is limited by a back wall 22 which includes therethrough a plurality of equally laterally spaced apertures or cavities 24, each of which is provided for receiving therethrough a portion of terminal 16.

The housing 12 further comprises an integrally connected rectangular and substantially flat platform or base 26 which extends the width of and rearwardly from the lower half of back wall 22. The platform includes a plurality of laterally spaced semi-cylindrical channels 28 extending across the entire top surface thereof and aligned with the apertures 24 of back wall 22 for supporting the crimping ends of terminals 16 which snugly fit within the channels for inhibiting lateral movement thereof. In addition to supporting the crimping ends of terminals 16 the platform acts as an effective anvil or counter-die during the crimping operation, as will be seen hereinafter.

Turning to FIGS. 3, 5, 7 and 8, various aspects of the terminals 16 are shown. The terminals are similar to the one described in US. Pat. No. 3,178,673, issued to J. H. Krehbiel, and therefore will not be described in detail. Briefly, each terminal 16 may be separated according to function into three longitudinally extending portions; a wire-engaging or crimping portion 30, a housing-engaging portion 32 and a terminal-connecting portion 34, shown best in FIG. 7. With respect to the wire-engaging portion 30, a first ferrule 36 having a semicylindrical base 37 is arranged to engage an insulated portion 38 of lead wire or conductor 14. Forwardly of the first ferrule 36, structure is provided in the form of a second ferrule 40 having a semi-cylindrical base 41 so that the terminal 16 may be electrically connected to the lead wire 14, the second ferrule being adapted to engage the metal wire portion 39 thereof. Being that the terminal 16 is of stamped sheet metal construction, the ferrules 36 and 40 are presented to the lead wire 16 in an open and slightly inwardly position, as shown in FIGS. 3 and 8. Thereafter, the ferrules are crimpedinto engagement with the lead wire in a manner which will be described hereinafter.

The central or housing engagement portion 32 includes wing-like, lateral flanges 42 which are arranged longitudinally forwardly of the second ferrule 40 and extend in a diametral plane in opposite directions from one another, shown best in FIGS. 3' and 7. In function, the wing flanges arrest forward movement of the terminal 16 with respect to the housing 12 by engaging the back wall surface of back wall 22.

Slightly forwardly of the lateral flanges 42, the terminal merges into a frusto-conical body 44 resembling a skirt having a rearward marginal extent exceeding the upper marginal dimension whereby the portion of the body 44 is sized to be slidingly received within a corresponding aperture or cavity 24 in the back wall 22, the shape of the body affording a degree of resilience in a radial plane for facilitating insertion therein.

Surmounting the body or skirt 44 is a pair of rearwardly and outwardly directed spring fingers 46, each arranged on an opposite side of the terminal 16. Being struck from the side walls of the terminal in the region of the body or skirt, the free ends of the fingers 46 extend toward the wing flanges 42 and are disposed laterally apart adistance somewhat greater than the widest lateral dimension of the skirt. Thus, as the terminal is inserted through the aperture 24, the fingers arecompressed inwardly against the skirt and snap outwardly when full insertion of the terminal effected. When the terminal is in the fully inserted position, as best seen in FIG. 7, the ends of the fingers engage the forward surface of. back wall 22 for preventing the terminal from being pulled rearwardly out therefrom. The distance between the free end of the fingers 42 and the edges of the wing flanges confronting them, is selected in direct correspondence to the thickness of the back wall 22.

. From the above, it follows that cooperation between the spring fingers 46 and the wing flanges 42 effects forwardly longitudinal movability of the terminal 16 with respect to the housing 12 for inserting the terminal-connecting portion 34 into an aperture 24. Once the terminal has been inserted into the aperture, the spring fingers and flanges prevent movement therefrom, the wire engaging portion 30 thereof being positioned in a corresponding channel 28 for preventing lateral movement.

The head or terminal-connecting portion 32 of the terminal 16 is dome-shaped at its outermost end thereby to define a head portion surmounting a somewhat narrowed neck 48, both of which cooperate for receiving an external female terminal (not shown).

It is to be recognized that the male terminal 16 is freely interchangeable with a female terminal (not shown), the female terminal being identical thereto except that the terminal connecting portion thereof includes an opening at its outermost end as opposed to a closed dome-shaped end for receiving an external male terminal. 1

The manner of assembling the multi-conductor electrical socket is as follows: Each terminal 16 is inserted into a corresponding aperture or cavity 24 in the housing 12 so that its terminal connecting portion 34 extends into the opening for receiving an external cooperating terminal. The portion of the terminal rearward of the back wall 22 is positioned in a corresponding channel 28 in the platform or base 26 and is supported thereby, the channel preventing the rearward portion of the terminal from lateral movement as stated above. Once the terminals have been so positioned, lead wires or conductors 14 are positioned adjacent thereto so that their insulated portions 38 and exposed metal wire portions 39 lie within and between first and second ferrules 36 and 40, respectively. All of the terminals and corresponding lead wires are thereafter substantially simultaneously crimped or forged together.

In order to achieve the simultaneous crimping or forging operation, there is provided a substantially rectangular die 50 extending the width of housing 12 and including a stamping or forging surface 52. As seen best in FIG. 8, the stamping or forging surface of the die contains a plurality of equally laterally spaced recesses transversely extending the entire width thereof, each of the recesses comprising two adjacent semi-cylindrical surfaces 56 which meet into a central ridge 58. As the recesses extend from the right side to the left side of die 50, as viewed in FIG. 5, it can be seen that the diameters of the-surfaces 56 sharply decrease so as to form two distinct recessed portions 60 and 62, which are of sufficient dimension so as to engage and crimp the ferrules 36 and 40 to insulated portion.38 and exposed wire portion 39, respectively, as will be seen hereinafter.

The die 50 is positioned above platform or base 26 of housing 12, as seen in FIGS. 3 and 5, so that the recesses 54 are in direct vertical alignment with corresponding terminals 16, the recessed portions 60 lying above corresponding ferrules 36 and the recessed portion 62 lying above corresponding ferrules 40. With the die so positioned, it is stamped or pressed downward against the top surface of platform 26 in a conventional die-stamping manner, the platform providing an effective anvil or counter-die. During a stamping operation, the upper ends of each'of the ferrules 36 and 40 are forced along adjacent semi-cylindrical surfaces 56 and eventually meet over the central ridge 58 for crimping together the terminals and associated lead wires. FIG. 9 shows the crimped ferrule 40 in combination with the exposed wire portion 39, while FIG. 10 shows the crimped ferrule 36 in combination with insulated portion 38. f i I While a simultaneous crimping operation has been disclosed, it is to be understood that the invention contemplates and the structure provides for a single crimping operation as well. That is, the terminals can be positioned and crimped one at a time by utilizing either the same or a modified die.

In order to add strength to platform 26 and prevent the same from moving laterally during the crimping operation, the housing 12 includes laterally spaced rectangular channels 64 extending the entire length thereof and positioned directly below corresponding channels 28. The housing may then be supported on a platform or table 66 which includes transversely extending longitudinal abutments 68 which are positioned and dimensioned for snugly entering respective channels 64 as seen in FIG. 8. Thus, as the die 50 is stamped against platform 26, the force resulting therefrom is transmitted to the abutments which in addition to receiving. such force prevent the platform from moving out of alignment with the die and limiting resilient deformation of the plastic material.

The housing 12 preferably includes an integrally connected cover 70 which is movable, either by automatic or manual means, between an open position as seen in FIGS. 3 and 4 for exposing the terminals 16 during crimping operations and a closed position as seen in F IGS. l and 2 for completely enclosing the terminals after crimping operations.

The cover comprises a top rectangular portion 72 integrally connected on its rearward edge thereof to a perpendicular back portion 74 both of which extend the entire width of the housing. The top portion 72 of cover 70 includes a tapered or thinned-out forward edge 76 which is integrally connected to the back top surface of the plug connecting forward portion 18 of housing 12, the tapered or thinned-out edge providing the appropriate flexibility required for moving the cover between its opened and closed positions. The otherwise free edge of side portion 74 includes a plurality of equally laterally spaced semi-cylindrical grooves or indents 78 which fit around the crimped ends of terminals 16 when the cover is in its closed position as best seen in FIG. 1.

In order to completely enclose the terminals, a flexible side flap 80 is connected to each side of cover 70 and includes a connecting arm 82 which may be conventionally connected to the bottom of housing 12 for maintaining the flap in its closed position as seen in FIGS. 1 and 2.

Turning to FIGS. 11 and 12, a modified cover 84 and a modified platform or base 86 are shown. The cover and platform are functionally identical to cover 70 and platform 26, respectively, the difference residing in the manner in which cover 84 is connected to platform 86. Specifically,'cover 84 includes a structurally different back portion 88 (as compared to back portion 74) which comprises a plurality of equally laterally spaced and partially resilient fingers 90 extending downward from a top portion 92 and between two rigid side portions 94 (only one of which is shown), semi-cylindrical grooves 96 being provided between the fingers for receiving the crimped ends of terminals 16.

A bottom end of each finger includes a downwardly facing and inwardly extending margin 98 which rests on the platform 86 when the cover is closed, and an angled flange portion 100 having a top margin 102 which extends to one side of the finger and which faces upwards for securing the cover to the platform, as will be described hereinafter.

Referring specifically to FIG. 12, platform 86 includes a plurality of laterally spaced ridges 104 extending across the entire top surface of the platform for defining channels 106 which are aligned with apertures 24 of back wall 22. As viewed in FIG. 12, the left-hand ridge of each channel, except for the furthermost left-hand channel and the furthermost right-hand channel (not shown), includes an angled flange 107 having a bottom margin 108 which extends to one side of the ridge and which faces downwards for cooperating with top margin 102 of a corresponding finger.

As cover 84 is closed over platform 86, the lower end of each finger enters between two adjacent channels with its angled flange 100 being slightly compressed by a cooperating flange 107 until the margin 98 of the finger engages a portion of the platform between the channels. At this time, the flange 100 snaps back to its original shape, so that its margin 102 locks against an associated margin 108, thereby locking the cover to the platform.

While a particular embodiment of the invention has been shown, it should be understood, of course, that the invention is not limited thereto since many modifications may be made. It is, therefore, contemplated to cover by the appended claims any such modifications as fall within the true spirit and scope of the invention.

The invention is claimed as follows:

1. A method of assembling a multiconductor electrical connector comprising providing an insulated housing having a cavity with a wall at an end of said cavity and with apertures through the wall and with a base projecting from the wall in a direction away from said cavity, the base having channels therein approximately aligned with the respective apertures; providing a series of terminals each having an elongated body portion at one end and a ferrule portion at the other end; assembling said terminals with said connector by inserting said elongated body portions into said apertures such that the elongated body portions extend into said cavity and the ferrule portions extend into said channels for anvil support and lateral positioning thereof along said base, positioning electrical conductors in said ferrules respectively, and thereafter deforming said ferrules by a die-couple that includes a die member and said base with the channel surfaces forming anvil surfaces against which the ferrules are forced for crimping.

2. A method according to claim 1 in which there are two adjacent ferrule portions at one end of each terminal, the ferrule portions being of different perimetral size, and the die member has recessed portions of difl erent perimetral size for deforming said ferrule portions.

3. A method according to claim 1 in which the base has additional channels longitudinally aligned with the first-mentioned channels and opening to a face of the base that is 0pposite to the face at which said first-mentioned channels are open, said additional channels receiving abutments to assist in maintaining the base and die in alignment.

4. A method according to claim 1 further including providing a cover for said housing that is attached to said housing in a position that exposes said ferrule portions for said die-crimping, and after the diecrimping moving said cover to a position overlying the crimped ferrules to enclose them.

5. A method of assembling an electrical connector comprising the steps of providing an insulated housing with a base having channels opening on one face thereof, said housing also having a wall with recesses therein, providing a series of electrical terminals each having a portion thereon for crimping to a conductor, positioning said terminals in said recesses such that the crimping portions are on said base at a face thereof that is opposite to the face at which said channels are located, positioning conductors in said crimping portions and positioning abutment members conformably in said channels to support said base with the material thereof interposed between the channels and recesses, and thereafter die-deforming said crimping portions about said conductors by use of the recess surfaces as anvil surfaces and said abutment members as a backing to said anvil surfaces to stabilize the position of said base relative to the deforming die.

6. A multi-conductor electrical connector comprising an insulated housing having a cavity with a wall at an end of the cavity and open at the opposite end thereof and with spaced apart apertures through the wall, a base projecting from said wall in a direction away from said cavity, the base having elongate channels therein approximately aligned with the respective apertures, a series of electrically conductive terminals each having an elongated body portion at one end and an initially open ferrule at the other end, said body portions being in said apertures respectively and extending into said cavity, said ferrules being seated in said channels respectively, and a conductor received in each ferrule, each ferrule being deformed by means operating on the open end of each channel-seated ferrule to crimp the conductor therein and with each channel sufi'iciently elongate to underlie the entire crimped portion of an associated ferrule.

7. A connector according to claim 6 including a cover movably mounted on said housing from a position wherein the crimped ferrules are exposed to a position wherein the crimped ferrules are covered. I

8. A connector according to claim 7 in which said base has additional channels opposite to said first-mentioned channels the two sets of channels opening to opposite faces of the base. 

1. A method of assembling a multiconductor electrical connector comprising providing an insulated housing having a cavity with a wall at an end of said cavity and with apertures through the wall and with a base projecting from the wall in a direction away from said cavity, the base having channels therein approximately aligned with the respective apertures; providing a series of terminals each having an elongated body portion at one end and a ferrule portion at the other end; assembling said terminals with said connector by inserting said elongated body portions into said apertures such that the elongated body portions extend into said cavity and the ferrule portions extend into said channels for anvil support and lateral positioning thereof along said base, positioning electrical conductors in said ferrules respectively, and thereafter deforming said ferrules by a diecouple that includes a die member and said base with the channel surfaces forming anvil surfaces against which the ferrules are forced for crimping.
 2. A method according to claim 1 in which there are two adjacent ferrule portions at one end of each terminal, the ferrule portions being of different perimetral size, and the die member has recessed portions of different perimetral size for deforming said ferrule portions.
 3. A method according to claim 1 in which the base has additional channels longitudinally aligned with the first-mentioned channels and opening to a face of the base that is opposite to the face at which said first-mentioned channels are open, said additional channels receiving abutments to assist in maintaining the base and die in alignment.
 4. A method according to claim 1 further including providing a cover for said housing that is attached to said housing in a position that exposes said ferrule portions for said die-crimping, and after the die-crimping moving said cover to a position overlying the crimped ferrules to enclose them.
 5. A method of assembling an electrical connector comprising the steps of providing an insulated housing with a base having channels opening on one face thereof, said housing also having a wall with recesses therein, providing a series of electrical terminals each having a portion thereon for crimping to a conductor, positioning said terminals in said recesses such that the crimping portions are on said base at a face thereof that is opposite to the face at which said channels are located, positioning conductors in said crimping portions and positioning abutment members conformably in said channels to support said base with the material thereof interposed between the channels and recesses, and thereafter die-deforming said crimping portions about said conductors by use of the recess surfaces as anvil surfaces and said abutment members as a backing to said anvil surfaces to stabilize the position of said base relative to the deforming die.
 6. A multi-conductor electrical connector comprising an insulated housing having a cavity with a wall at an end of the cavity and open at the opposite end thereof and with spaced apart apertures through the wall, a base projecting from said wall in a direction away from said cavity, the base having elongate channels therein approximately aligned with the respective apertures, a series of electrically conductive terminals each having an elongated body portion at one end and an initially open ferrule at the other end, said body portions being in said apertures respectively and extending into said cavity, said ferrules beIng seated in said channels respectively, and a conductor received in each ferrule, each ferrule being deformed by means operating on the open end of each channel-seated ferrule to crimp the conductor therein and with each channel sufficiently elongate to underlie the entire crimped portion of an associated ferrule.
 7. A connector according to claim 6 including a cover movably mounted on said housing from a position wherein the crimped ferrules are exposed to a position wherein the crimped ferrules are covered.
 8. A connector according to claim 7 in which said base has additional channels opposite to said first-mentioned channels the two sets of channels opening to opposite faces of the base. 